Moulded cover jack assembly



Sept 6, 1955 G. o. PUERNER 2,717,367

MOULDED COVER JACK ASSEMBLY Filed Jan. 27, 1954 2 Sheets-Sheet l INVENTOR fmlggfe d Puernef lllllllllllllulllllh l nul 'I4 ATTORN EY Sept. 6, 1955 Q O, PUERNER 2,717,367

MOULDED COVER JACK ASSEMBLY Filed Jan. 27, 1954 2 Sheets-Sheet 2 INVENTOR flea/re d Bie/wer ATTORNEY United states Patent o" MOULDED COVER JACK ASSEMBLY George 0. Puemer, Indianapolis, Ind., assignor to P. R. Mallory & Co., Inc., Indianapolis, Ind., a corporation of Delaware Application January 27, 1954, Serial No. 406,439 15 Claims. (Cl. 339-185) The present invention relates generally to electrical connectors and/or jacks and has particular reference to barrier type devices including means and methods for waterproofing the same so as to allow the use thereof with associated equipment in submerged environments.

. It is `sometimes necessary to interconnect electrical devices and apparatus such las communication and audio equipment as well as potentiometers, rheostats, switches and meters conned within a control or junction box which may itself be in a submerged environment or atmosphere of high humidity. Any connection. moreover, to such latter apparatus, which is usually mounted on the interior wall of the aforesaid junction box, must be made in a manner so as to substantially preclude the inllow of liquid from gaining access to such submerged equipment and which wouldperhaps damage the same irreparably. v

To prevent this, connections are made between such equipment by means of an electrical jack structure which may in turn be mounted on the interior wall of a con-` trol box or junction box. It is apparent, however, that the construction of such a jack must be of such nature that the water surrounding such a junction boxA will be prevented from gaining access thereto and influencing the equipment. Since each jack has an ingress aperture or hole adapted to mate with its corresponding plug section or component, the interior of such jack must be constructedin a manner which will prevent or block any ow of water seeping thereto from continuing and penetrating through said jack interior to the associated electrical equipment.

It is therefore a prime object of the present invention to provide a novelhigh humidity and water-resistant jack means for interconnecting electrical equipmentV and cornponents whereby the said equipment will be allowed proper operation without being iniiuenced by the moist surrounding environment.

It is another object of the present invention to provide a waterproof type of jack which is adapted to interconnect equipment with associated plug connectors and whereby a liquid, although penetrating said jack aperture, may be prevented from reaching said associated electrical equipment. .Y

Another object of the present invention is to provide av barrier type jack constructed in a manner so as to allow waterproof operation ofassociated electrical equipment connected to s aid jack which is in turn connected to an associated plug. v

Another object of the present invention is to provide an expensive andnovel waterproof jack.

Still another object of the present invention is to .provide a waterproof jack inpwhich the construction is such as to enable the ready use `of the same in a submergedV environment.

Anothei object of the present invention is to provide a jack which is simple, strong'and durable in construction.

-' Still another object of the present invention is to proi j 2,717,361 Patented Sept. `6,r 1955 vide a simple, eficient and practical waterproof and/or barrier type jack for use in interconnecting associated electrical equipment. n p 1 Another object of the present invention is to provide a waterproof type jack which includes a plastic, molded shell fabrication and is novelly constructed and adapted for positively mounting and supporting a spring construe-lv vention consists in the construction, combination and arrangement of parts hereinafter described and illustrated in the drawings, in which: i,

Fig. 1 is a side elevational view of an embodiment of the novel water-seal jack of vthe present invention as adapted to illustrate the relationshipbetween the outer and internal sections thereof;

Fig. 2 is a longitudinalcross sectional kview ofv an embodiment of the present .invention as adapted to illus-r trateV the assembled relationship of the various components in the waterproof jack construction thereof and as taken along line 22 of Fig. 1; l

Fig. 3 is a cross-sectional view ofthe vrearof the waterproof jack talienV along line `3 3vr of Fig. 2 and as adapted to show the novelvvaterproof yinternal rubber,

pockets surrounding the' metal resilient springs of the jack;

Fig. 4 is an illustrative view of theinternal spring' c on-V struction of the waterproof jack showing the lVshaped. resilient spring tip and sleeve assembly; Figs. 5 and 6 arel illustrations of .the individual resil-` ient tip and sleeve vsprings utilized in` the aforesaid invention of a waterproof jack andas shown in Fig.` 4;, i

Fig. 7 is a modification of the, embodiment ofthe invention shown above whereina braided shield is placed over the waterproof jack andpwhere the solder lugs are connected to a conductor whose leads are further protected by a moisture-proof enclosure, with said braided shield overlying the fsameand being connected to the shell of'said jack; and

Fig. 8 is a modificationY of the structure shown in Fig. 7. having an additional metal shield placed over the n jack and braided shield structure.

gitudinally in both top and bottom inner walls rthereof in a manner such that the top wall structure has its slots separated by meansof a wider partition than the lower slot structure. As so constructed the inner side walls of the shell converge toward each other so that specially Y constructed resilient side spring frames preferably fabricated of silver plate copper alloy strips are adapted to slide within both the top slots and the lower slots to form a plug gripping means having a different angle at the top than at the bottom.` l

The frames of the resilient springs are adapted to d penetrate. through the backwall of the shell via a pair of slots cut therethrough essentially inthe same axial plane as the slots formedin theinner wall of said shell. The frames include unitarily'fabricated solder lugs which are adapted to pass throughthe slots in the back of said shell so as to accommodate and join the termini of associated conductors. The metals usedl therefor are the same as for the frames and are hot tinned for easy soldering. A spacer disc aids in the retention of the frame within the slots of the shell While at the same time a rubber sleeve having pockets. therein surrounds the individual solder lugs so as to prevent any water from passing through the back wall of the shell.

Over the front end or collar of the shell an annular metal cap or cup having a threaded bushing structure is fitted. The sidewall of the cup is scalloped so as to provide clutching teeth to retain the cap` on the collar of the shell` by crimping these teeth thereover. A unitarily constructed solder lug extends from this cap structure tok be used for connecting a conductor. Inside thel cap a rubber gasket and fibre washer surrounds the internal bushing opening, The construction as above explained and subsequently described in greater detail hereafter, is thus adapted to provide a, waterproof type of jack capable of being usedI with cooperating electrical equipment so as to prevent the ilow of, water to said equipment.

Referringnow to the drawings and more particularly to Figures l, 2 and 4, there isvshoswn a waterproof jack 1t) having a unitarily molded, prefabricated shell structure 11 comprising a main cylindrical body portion 12 and an annularly configured collar portion 13 which is wider in diameter than the main body portion of the shell and which is interconnected theretoby means of a shoulder 14. In Fig. 4, the` annular collar 13l is shown as cornprising a neck portion having a circumferential side wall 14 and a tapered ridge or lip 15 extending therefrom, The shellcornprises a front open-faced portion having a wide central aperture 16 through which a pair of resilient contact spring means 17 andk 18 for makingconnection to the tip and sleeveV of an associated plug is adapted to pass. The shellhas an opposingl end Wall 19 which is substantially closed exceptfor two slots 20 and 21 which are cut therethrough so as to allow solder lugs 22 and 23 of the said-resilient tip and sleeve spring means 17 and 18 to pass therethrough andthus to be connected to outside connectors. The inside wall of the shell has cut therein a pair of guide slots 24, 25 disposed in the top half thereof, said slots having a wide ridge 26 separating them, and a pair of guide slots in the bottom half thereof, 27, 2S which slots are separated by a ridge 29 substantially narrower than the top as above stated. The guide slots betweenthe top half and the bottom half of the side wall are interconnected by means of a pair of side ridges 30 and 31. The spring guide slots extend the entire length of the shell toend next the back wall thereof. The back'wall of said shell is kintegrally molded to the annular side wall of the shell and has a pair of apertures, as stated, cut therethrough which apertures are angulated to receive the pair of solder lugs connected to the spring frames of the jack.

The cup structure 30 of the jack adapted to fit over the collar portion of said shell comprises a metal threaded bushing 31 staked to a stamped metal front surface 32. The center of the front surface has a circular aperture 33 substantially of the same diameter as the hole in the bushing which is to accommodate the diameter of the insertable plug. The front surface about the circular aperture comprises a circumferential raised ring portion 34 and a countersunk inner land portion 35 adapted to contain thereby about said bushing, if required, a disc-shaped rubber washer. The inner face of the countersunk center portion of the front surface is thus pushed inside the cap to form an annular groove between the cap side wall which is fabricated to extend back from the face of the cap. This inward groove also is adapted to accommodate a rubber gasket between the walls of the groove. A libre washer 4-1 is also adapted to be seated on said inner surface of said countersunk portion of the cup. As seen, the annular side wall Sti of the cap or cup extends on the collar of thernolded jack shell and is adapted to tit-thereon. The vend ofthe side wall of the cap is scalloped to form a plurality of teeth 51 which, when said cap is fitted over the shoulder of the shell, are adapted to extend beyond said collar thereof so that they may be crimped along the shoulder and to firmly seat the cap on the shell. A solder lug 60 unitarily formed and connected to said cap extends backwardly in a plane parallel to the side wall of said'- shell but is spaced therefrom.

Figs. 4, 5 and 6 show the contact means for making contact between tip and shell of a cooperating plug for the jack. These means comprise resilient frame spring constructions including a pair of substantially rectangular configured spring frames 17 and-18. The spring ,frames comprise longitudinally extending side walls 70, 71, 72V

and 73 made of thin strips of'rnetal, which side walls are joined by means of thin end walls 74-77 as particu-` larly shown in Figs. 5 and 6. An end wall of the resilient spring frames has individual solder lugs 22 and 23. integrally formed and connected substantially at the` center` thereof. The solder lugs are adapted to fit through their cooperating libre washer 80. and rubber sleeve 81. prior to penetrating theback wall of said plastic molded shell.

One of the end walls parallel to and opposing said solder lugs may be bowed slightly in construction to, aid in their resilience and may have integrally formed therewith and extending within the space surrounded by said. frames, tongues or resilient springs 82 and 83 inclined' inwardly away from said rectangular shells and toward, their corresponding opposingI frames. The two rectangu lar frame springs have a cradle-like configuration adapted to be held by slots falling back from the center openend of said plastic shell toward' the closed end thereof. Each, tongue portion of the resilient frame comprises a tapered inclined main section 85, 86 and V-shaped portion 87, 88. connected thereto by means of inclined side walls which thus form a contactridgefon electrically Wipingand gripping the tip or shell of the accommodating plug which is insertablebetween the resilent frames.

The resilent frame structures are insertable within insulative spacer or washer 80 at the backA end thereof. The insulative washer 80 may be constructed of. abredisc having annular side walls 90, 91 and crosswise connectingvat topy walls 92, 93. A pair ofslots 9 4,` 95may be cut therethrough with said slots converging toward each other. The solder lugs connected to the resilient frames are ttable therethrough. A rubber sheath 81. having; a

thin annularV face 100 and integrally joined pockets 101,V

102 of a tapered Vconstruction is adapted, to, havesaid Y pockets penetrated by the solderl lugs and to allow the pockets to adhere tightly aboutthesame. the resilient spring framesareslid within the slots-formed in the inner wall of the'shell sothat. the solder. lugs pass through the aperturesin the-backfwall thereof the spring structure is adapted to be maintained and positively aligned withinl said, slots and to", bey supportedat the front and'back of the shell in anextremely resilienty yet tightly tting manner. .A 4

in. the Vassernblyj of` thev waterproof jack, above der scribed, the internal assemblyv comprising the rectangular resilient frames have their individual solder lugspass through the. fibre spacer. VThe thirrrubber sheath and pockets are then passed over the ends of the solder lugs so that a rubber-layer essentially surrounds theflat sur.- face of the spacer discand the legsof solder lugs. The

leg ends of the solder lugs, in assembly, are then forced against the thinclosed end4 wall of the rubber pockets so that they are pushed therethrough. Next, the inner spring assembly is slid along the slots formed. in the face of and the inside sidewall ofthe moldedshelluntil the solder lugs pass through the aperturesin the back wall thereof. Finally the cap, including the inside gasket andbre washer and having the centrally connected outside, threaded bushing, is tted over. the shoulder. of: the moldedzshellV and the teeth formed by the scalloped end of the cap; arecrimped vagainstthefshoulder to-- tightly. clampthesa-me thereto. Further, in fittinglthe jack to any panel,,a;rubber,.

gasket (not shown) may be externally provided, tosurround the bushing. 1

In Figs. 7 and 8, modicationsof the structure above disclosed are shown, wherein additional protection may be afforded to the devices. As seen in Fig. 7, the solder lugs of the jack are connected to an external conductor having a braided sheath orlsleeve 106. The connections 107, 108 thus made are protected by plastic hollow tube 109, 110 covering the individual lugs.

the jack described in the; other gures. The braided sheath is passed under the cap prior to crimping vthe same over theshoulder of the shell. Thus, the braided sheath is also tightly clamped within of said jack shell.

In Fig. 8, an additional protecting metal or aluminum can 112 -is placed over thebraided sleeve construction.

shown in Fig. 7 and allows for electrical shielding of the jack, and may be lused additionally wheresuch shielding is desired.

The invention of the waterproof jack'lhereinabove described is merely illustrative of its manner and mode of operation and construction and the inventionis not to` be restricted in scope thereto but is to take its breadth-rather from the claims here appended.

What is claimed is: s

, l. A jack comprising a plastic moulded shell including an annular side wall having a plurality of converging slots extending along the length thereof, a substantially closed back wall, an open end opposite said back wall, a pair ofv contact springs, each having a surrounding integral sup,-

porting frame, said frameshaving solder lugs penetratingy said back wall and being held in said'slotsyalong said.

2. A waterproof jack comprising an integrally mouldedl plastic shell including a main bodyfportionand aneck portion, `said neck portion being connected tosaidfmain body portion by means of ashoulder, aback wall for said plastic shell being substantiallyrclosed save for a pair; of, slots penetrating therethrough and.. converging toward each other, said main body portion including a plurality `of longitudinally extending alignment slots` formed therein,

an open end for said shell placed opposite said backwall, at the front thereof, a pair of contact springs, each having an integrally formedsurrounding supporting frameworkincluding extending solder-lugs centrally connected thereto at the back of saidvshelL said solder lugs adapted to. pass through said slot apertures in said back'wallso as to converge said framesin accordance with-the direction of said slots, said frames further being held in said :slotsgof said main body portion, and a capstructure having toothed. f

gripping means integrally formed at any end thereof for closing said open end, said cap adapted to t over said` neck of said jack with said teeth Athereof adaptedtoclose over said shoulder to clamp the same firmly thereto,` saidcaprhaving a'central aperture kadapted to allowfa conf.. nectorplug to pass therethrough so as to be gripped by said converging frames includedwithin said plastic moulded shell of said jack. v A.

3. A waterproof jack comprising a ,unitarilygnoulded plastic shell, said shell being hollow and having a cylindrical body portion with an annular side wall,l a back wall thereto being closed except for a pair of narrow converging slots penetrating therethrough, the opposite `end of said shell beingopen-,'a collar section of a widerA diameter connected to said open end of said body portion of said shell, a pair of contact springs supported in the wall of said body portion, said springs having solder lugs con nected thereto adapted to penetrate said back wall through said slots therein, and a cup fitting over said collar of said shell, and means for clamping'said cup over said col- Braided sheath or sleeve 106 is passed over the cap and plastic shell of said cap on said shoulder lar to-tightly grip` the same,vsaid.cup having an'apertureY gripped -by adapted to receive an associated plug to be the contact springs in said jack.A

narrow converging slots penetrating therethrough, lthe opposite end from said backend of saidshell being substantially open, a collar section ofl -wider diameterconnected to said open end of saidbody portion of said shell, a pair of rectangular frame contactrsprings having the centers Athereof :open and Ysupported in the wall vol? said body portion, said springs havingfsoldenlugs iin-f tegrally connected thereto ladapted to penetratesaidback. wall through said slots therein, and a cuptitting over said collar of said shell, and' means for clamping-said cup over said collar to tightly grip the same,said'cuphav'- ing an aperture adapted to receive an associatedplugt be gripped by the contact springs in said jack. 5. A waterproof jack comprising aunitarily moulded plastic shell, said shell being hollow and having'ascylindrical bodyportion with an annularside wall,-said ywall having a plurality of slots, a back wall connected to said shell being substantially closed except for a pairof'narrow converging slots penetrating therethrough, the end of said shell opposite said closed end being substantially open, a hollow collar section of a wider diameter connected to said open end of said body portion of vsaid shell, a pair of tip and sleeve contact frames supported --invthe opposing slots of said'wall of said body portion, said springs having integrally formed soldery lugs connected thereto at` the center of eachl frame adapted to penetrate sadbackl wall through said slots therein,- a cup fitting oversaid` collar of said shell, and means for clamping! said cup over said collar to tightly grip thesame, saidV cup having an' aperture adapted'to receive an' associated.pl`ugr to be: gripped by the contact springs in-said jack. -;v i 6; ,A waterproof jack comprising aunitarily" mouldedV cylindrical plastic shell, said shell being centrally hollow and having a body portion with' an annular side wall, a;

penetrate saidback wall through said slots therein,- `a cup fitting over said collar of saidsl1ell,;=and,integrally formedteeth means connected to said cup for,clampingsaid cup overl said collar to tightlyv grip the-shoulder ofsaidgshell, saidV cup having an'ape'rture adapted toy receive `an associated plug to `be gripped by the contactfspringsrin said jack.y 1 'f 'i 7. A waterproof-.jack'comprising a unitarilymulded cylindrical plastic shell, said shell being centrally' hollow and having a cylindrical bodyportion /with an annular side wall, said side wall having a pluralityo'fslots th'r'el in, a back wall connected at an end thereof being sub-v stantially closed except'for a pair of narrow .convergingk apertures penetrating the thickness thereof, the yopposite4 end of said shell being substantially open, a .collar section of a wider diameterconnectedto said openendof said body portion of said shell by means of av shoulder, a pair. of contact tip and sleevespringsV of yframe configuration supported in the wall slots of said body portion,-saidY springs having centrallyextending'solder llugs connected thereto forpenetrating through said backwalll slots, a metal cup titting oversaid collar'oflsaid shell-,x

and scalloped end meanson said. cup for'clamping said cup oversaid collar along saidshoulder to tightly grip the same', saidcup having a'n aperture adapted to receive arrasar' anassoeiated plug: tobe` gripped' bythe `contact springsirr 'said jack. Y l

8. A jack comprising a plastic moulded sheill having al main" bodyaportion andi an interconnected wider neck portion, a -baclc wall substantialiy closed save for apair of slotsv penetrating the thickness thereof, an open end to. said shell at a point opposite said; backwall, said open end having anannular centraly aperture, a pair of rectangularV spring frames held within. said main body portion of said` shell, said frames having ay pair of solder lugs each. adapted to pjass through the back thereof through said` slots of said back-wall', and a cap for closing said open end, said: cap having an aperture concentric with said centralY apertureV of said shell and adapted to. allow a connecting plug to passitherethroughsoas to2 be gripped' bysaidframesi Y 9. A. jackA comprising amicatilled phenolic moulded Shelli` having a mainY body` portion underlying a plurality of slots; a="wider neck port-ion having a`y central aperture, said neck and shell being interconnected by a shoulder, aback wail substantially' closed vsave for a pair of converging slotsv entirely-penetrating the thickness thereof connectedto said shell, an open end. for said' shell at the end furthest from said back wall, said open end having an annular central` aperturey aligned. with said neck aperture, apair of rectangularl metalspring frames held withinl said slotsof said main-body portion of said. shell, said frames further: having a pair of. solder lugs each:v adapted to passv through the back of said shell through the slots thereof sorastoconverge the frameswithin said. shell; and a rnetal cup for closing said open. end, said cup having an apertureconcentric. with said centrali aperture of said shell and adapted to'` allow: a connecting plug toy pass therethrough so as: to begrippedby saidL converging frames,

l0. A jack comprising a mica lled molded shell havi portion? of, said shell;Y said: frames further having'V a pair ofi soldenlugsiintegrallyjoined thereto, each adapted to passy through the: back of. said shell through: the slots thereon-so asztoonvergeand maintain. theframes oiV said shell,` and. a metal cup: gripping the said shell: on. the outside thereon for: closing said open end, said cup having f al1-aperture concenhfic'wi'th; said aperture of said .shelland adapted to:.allow a-connecting plug to pass therethrough so as tcrfbesgripped; by said; converging-frames.

121i'. Awbarrier typejack comprising a unitarily moulded;

plastic'shell! having) a. hollowjcylindrical. main. body Vpor-tA i tion and an interconnected wider neck portion having: a central aperturaa bacio Wall; substantially, closed savef'or apain-of narrow slots penetrating the thickness*thereof,l anopen end-to` said shell opposite said, backwall, said` opcnendhavinganannular central aperture aligned with. said neclcaperture, a` pair of rectangular spring framesl held, within said main bodyv portion of said shell, said frames having-fa pair, of solder lugs each adapted to pass through the back thereof through said slots of said back wall, and' a cap for closing saidopen end, said cap havingt a solder lug connected' thereto and a bushing concentric With saidv central aperture of said shell and adapted to'allowa connecting-plug to pass therethroughl seas-tobegripped by saidframes; 1'2. A-jaci comprising a piastic mouldedv shellhaving a main bodyv portioni and" an interconnected Wider neck' portion,A a baclc Wall substantially closed save for a pair otrslots: penetratingA ther thickness thereof, an. open. end; to-saidshell at apointi opposite said b aclr` vvall,saidL open. endhaving an annular central aperture, a-, pair of-` rec:-v

tangularspringframes held' within said inain body portion of said shell, each of said'fra'mes havingl a solder lug adapted to pass through the back, thereof` through said aperture, a cap for closing said open end, said cap having a solder lug and an aperture concentric with said central aperture of said shell, anelectrical conductor having a` pair of terminals, one of said terminals being individually connected to one of said iirst solder lugs, said connections: being covered by separate covers, and a braided sheath of said conductor clamped by said cap arid placed over said main' body portion of said jack and said connections covered by said' covers.

123.A A jack comprising a plastic moulded shell having a main body portion and an interconnected wider neck portion; aback wall substantially closed save for a pair of slots penetrating the thickness thereof, an open end to said shell at a point opposite said back wall, said. open end having an annular central aperture, a pair of contact springs, each hav-inga surrounding integrally supporting frame held within said main body portion of said shell, each of said supporting frames having a solderv lug adapted towpass through the back thereof through said. slots formed therein, a cap for closing said open end, said-1 cap having a solder lug andV an' aperture concentric withsaid central aperture ofsaid shell, an electrical conductor having a pair of individual terminals, one ot' said terminals being individually connected to one solder lug connected to each of said contact spring frames, saidindividual connections. being' covered by separate tubes, a braided sheath of said conductor clamped by said cap placed over said main bodyl portion of said jack and said connections coveredv by said tubes, and a metal shield placed over the braided sheath covering said main body portion of the. shell.

14. A jack comprising a shell having an annular side ing said` open end thereof, said cap having a central apertureadapted to allowV aplug to pass therethrough and to be gripped by the contact springs Within said i'ranic-V worlr..y 15; A jack comprising av plastic, Vr'nolded shell including a main body-portion and an interconnected wider neck portion, said body portion having a plurality of longitudinal alignment. slots-'formed therein, a substantially closedback Wailconne'cted tovs'aid main body portionl of saidshelh said back wall having a pair of slots penetrating therethrough and converging toward each other,

an open end for said main body portion, arpair of con-- f tactvsprings surrounded by integrally supporting spring frames. which have-length and side Walls, said contact springs thus being placed within the space of said frames and' being connectedto one wall ineach, solder lugs connected to anfend of said! frames and passing through said pair of slots-0f said back Wall to be supported thereby, said frames 'further-beinglield within said alignment slotsy of said` shell, and a cup for closing said open end o said? shell, said cup having afcentral aperture adapted to allow a connecting `plug to pass therethrough and to be'grippedv by said frames.

.References Citedi in the file'- oii this patent UNITED' STATES PATENTS Re.,20,03j3 Hudson` July 14, 1936 530,066 tartwright Nov. 24, 1894 .1,103,9911 `Murray, July 21, 1914 1,170,190 Ravlin Feb. l, 1916. 1,841,736 Jones Jan. 19, 1932 2,196,313'` ILoursent Aug. 9,V 1940 p 2,45,7", 48"S^ Penfo1d' Dec. 28;,1948' 

